The U.S. Air Force's recent technological initiatives are setting new standards for efficiency and sustainability within military and commercial aviation and transportation. One of the most notable advancements is the implementation of 3D-printed drag reduction components for the C-17 Globemaster III military transport aircraft, which are expected to yield significant operational benefits.
The U.S. Air Force is at the forefront of this innovation with the testing of specialized microvanes, which are thin blades measuring 4 x 16 inches. These components are strategically installed at the rear of the aircraft's fuselage to modify its aerodynamic profile, which is traditionally disrupted by the design of its cargo door section. According to Roberto Guerrero, the U.S. Air Force’s Operational Energy, Safety, and Occupational Health Deputy Assistant Secretary, "Every gallon of fuel saved strengthens our readiness and operational effectiveness." The microvanes are anticipated to reduce drag by 1% and result in yearly savings of over $14 million on fuel costs, showcasing how modern technology can revitalize legacy aircraft.
Live testing of these microvanes was conducted as recently as October 2023, validating their design under real-world conditions. These modifications will not only improve the aircraft's performance but also play a pivotal role in enhancing the Air Force’s strategic capabilities in the competitive environment of modern air operations. Guerrero noted, "By adding modern technology like microvanes to our legacy aircraft, we’re saving millions in fuel costs and building capability important for maintaining our competitive edge." With six C-17s already equipped with the microvanes, the Air Force is proceeding with logistics service assessments and planning to roll out the technology across the entire Globemaster III fleet.
Meanwhile, advancements are also being made on the ground: Donaldson Company has entered a partnership with Daimler Truck North America (DTNA) to integrate its air filtration technology with the next-generation Freightliner SuperTruck III. This collaboration is positioned within the U.S. Department of Energy's SuperTruck program, aimed at enhancing fuel efficiency and shrinking emissions for heavy-duty Class 8 long-haul trucks.
Since the SuperTruck initiative was launched back in 2011, it has catalyzed considerable progress, producing demonstrator vehicles from various manufacturers. The previous iterations of the program focused on optimizing diesel engines. Still, the latest project marks a transformative shift, as it pivots toward developing hydrogen fuel cell transport solutions—an approach seen as fundamental to the industry’s push toward greener operations.
According to Keith Bechtum, Donaldson’s Vice President of OEM Sales, "Donaldson Company and Daimler Truck North America have a long-standing partnership, collaborating on various filtration solutions for DTNA's commercial vehicles. We are enthusiastic to continue providing support for the SuperTruck III program." This commitment is expected to bolster the partnership and expedite the practical application of hydrogen technologies, with the DOE providing $26 million to support this innovative venture.
The insights gained from developing the SuperTruck III hydrogen fuel cell demonstrator could have broader applications, shaping the future of on-highway hydrogen fuel cell technology. This strategic collaboration exemplifies how industries can work together to revolutionize transportation technology, aligning with environmental goals and sustainability ambitions.
Both the Air Force’s exploration of 3D-printed components and the partnership between Donaldson and DTNA represent significant milestones toward efficiency and eco-friendliness within transportation sectors. These advancements not only project cost savings and performance enhancements but also reflect the growing imperative for military and commercial transport sectors to embrace sustainable practices. This technological evolution hints at what lies ahead—a possible paradigm shift toward greener, more efficient modes of transport, reinforcing the value of collaboration and innovation across industries.